Manufacturing Systems Research

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Manufacturing Systems Research
Chris Hicks
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Computer Aided Production Management Systems in
Engineer to Order Companies

• ACME grant in collaboration with NEI
• Objectives
• Identify the characteristics of companies in
  ETO/MTO sector
• Evaluate the status of CAPM
• Identify common CAPM problems
• Develop methods for modelling CAPM systems in
  ETO/MTO environments
• Apply modelling methods to identify solutions to
  CAPM problems

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Identification of Company Characteristics and
CAPM problems

• Nine one day visits
• Three long visits (3 days - 1 month)
• Developed semi-structured audit methodology
• Developed methods for company classification

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Audit

• Markets
• Products
• Processes
• Manufacturing Systems
• CAPM Systems

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Company Classification
Jobbing
Company Type A
Manufacturing Process
Batch
Main product
Spares
Subcontract
Flow
Shallow
Deep
Product Structure
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Company Type B
Jobbing
Manufacturing Process
Batch
Valves Pumps
Motors
Cabs
Flow
Shallow
Deep
Product Structure
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Control Approaches
Project Management
Jobbing
MRP
MRP JIT
Manufacturing Process
Batch
JIT
Flow
Shallow
Deep
Product Structure
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Audit Conclusions

• Markets - demand highly variable and lumpy
• Products - complex, highly customised, mix of
  products
• Processes - wide range yet all areas tend to be
  controlled in same way
• Manufacturing systems - mainly functional
  layouts, high capital employed
• CAPM systems - poor integration, wide variety of
  subsystems, incorrect data structures, poor
  operational procedures, generally unsuccessful

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Systems Modelling

• Functional models decompose complex systems using
  a hierarchical top-down approach. They provide a
  means of understanding activities and
  interrelationships
• Information models enable structure of
  information to be described
• Dynamic models show changing behaviour over time.

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Company X - Context Diagram
a
a
Customer
Customer
Contract
ITT
Awarded
Progress
Tender
Report
Company X
ITT
Quote
Order
b
b
Supplier
Supplier
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Method Limitations

• Audit, systems analysis and data modelling
  provide static snapshot views. Longitudinal
  studies are a series of snapshots. No model of
  system dynamics.
• At best enable best practice or potential
  solutions to be described and documented.
• Not possible to perform experiments to examine
  alternative configurations and evaluate them in
  terms of specified performance criteria

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Simulation

• Allows modelling of system dynamics
• Very expensive in terms of model building and
  computational resources
• Validation often a problem
• Predominantly used for either small scale models
  or rough-cut high level models

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Simulation Model CAPM Modules
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Key Features

• Large scale model allows whole manufacturing
  facilities to be represented
• Models facilities, products, processes and
  planning and control systems
• Many product families can be represented with
  shallow, medium or deep product structure
• Data structures match ETO/MTO requirements
• Allows variety of planning and control methods to
  meet local requirements
• May be used as a research tool or for planning
  and simulation.

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Simulation Case Study

• Heavy Machine Shop used for case study
• Static configuration used layout and other
  resource constraint information
• BOM information obtained for products
• Process data and planning data obtained for 18
  month period.

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Experimental Design

• Series of full factorial experiments
• Factors
• Process - assembly lead time, minimum set-up,
  machining and transfer
• CAPM, scheduling methods, BOMs, dispatching
  rules, capacity planning
• Product mix / load
• Operational - data update period

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Conclusions

• Assembly planning and capacity planning important
  CAPM subsystems
• Dispatching rules not very significant
• Manufacturing performance sensitive to transfer
  times.
• Significant advantages gained through having
  close control of key resources
• Real time data recording led to improved
  manufacturing performance

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Consequent research topics

• Manufacturing Layout (Hinrichs, Wall)
• Capacity planning (Tay, Holmes, Hines,
  Pongcharoen)
• Assembly planning (Sullivan ..)
• Planning of product development activities
• Planning under uncertainty (Wall, Brand, Song)
• Integration of project planning methods with MRP
  type approaches (EPSRC proposal)
• Plan Optimisation through Genetic Algorithms

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Manufacturing Layout

• All data required for layout analysis, clustering
  and generation in simulation data structures
• Work started with Chris Lee who was interested in
  improving the layout of Vickers Scotswood Road
  factory
• Much work in layout has focused on moving from
  functional layout to cellular layouts

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Methods

• Clustering
• Matrix based methods
• Similarity coefficient methods
• Layout generation
• Starting with some candidate solution generate
  new layout that minimises (maximises) some
  objective function
• Simulated annealing
• Genetic algorithms

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Capacity Planning

• Finite / infinite loading
• Re-planning rules (Tay)
• Finite loading rules (Holmes)
• Interactive tools (Hines, Poncharoen)
• Schedule optimisation (Poncharoen)

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Supply Chain Management

• ETO companies moving towards buy rather than make
• Business process analysis approach (McGovern,
  Earl, Harrison, Hamilton)
• Agent based modelling of supply chains (Harvey,
  McLeay, Hines)

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IT Implementation

• Embodies audit, business process analysis and
  requirements definition
• Transfer of computing expertise
• 3 Teaching Company Schemes

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Layout design effect on benchmarks

• Tony Wells Siemens Semiconductors
• Data from North Tyneside, US, Germany, Taiwan.
• Pareto analysis of costs
• Identification of cost drivers
• Relating cost drivers to plant design
  configurations
• Results so far potential cost reduction of 50
  on 30m/annum -pity the plant has closed!

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Management of Knowledge

• Data modelling / systems analysis based upon
  thematic knowledge that is formal, explicit and
  easily shared
• Knowledge management requires knowledge of
  product and process structure
• Tacit or embedded knowledge that is
  disorganised, informal, context dependent and
  relatively inaccessible often important.
• Interested in developing methodologies for
  systems integration that include both thematic
  and tacit knowledge
• LABS Proposal with Paul Braiden

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Other Activities

• 180k EDF grant with ISRU to develop distance
  learning material (Dave Stewardson Mark Gary)
• TCS with House of Hardy aimed at improving
  manufacturing efficiency (Rob Davidson Paul
  Braiden)

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Summary

• Wide portfolio of manufacturing systems research
• Various types of research undertaken from the
  theoretical through to applied.
• Market led rather than product led